Performance sports garments formed from single layer double-faced performance warp knit fabric and method of making same

ABSTRACT

Performance sports garments formed containing an integrally formed stretch warp knit fabric structure formed from a single layer fabric having definitive two-sided qualities. 1373-008

CROSS-REFERENCE TO RELATED APPLICATION(S)

This nonprovisional utility patent application claims the benefit of oneor more prior filed copending nonprovisional applications; a referenceto each such prior application is identified as the relationship of theapplications and application number (series code/serial number): Thepresent application is a Continuation-In-Part of application 10/720,947,which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates generally to textile fabrics and, moreparticularly, to a double-faced warp knit fabric for performance garmentapplications.

(2) Description of the Prior Art

Prior art includes reversible garments having different inside andoutside parts of the garment, typically provided by two fabrics joinedtogether at seams, i.e., woven or knitted fabrics that are later joinedtogether, wherein the two fabrics have a differing qualities, such ascolor, design or pattern, or texture. Examples include: U.S. Pat. No.6,647,551 issued Nov. 18, 2003 to Palumbo for Reversible garment; U.S.Pat. No. 5,561,860 issued Oct. 08, 1996 to Nguyen-Senderwicz forReversible two-toned and/or two-textured shirt/sweater with extendedsleeves; U.S. Pat. No. 5,204,995 issued Apr. 27, 1993 to Knapp forFashionable reversible pants; U.S. Pat. No. 4,310,929 issued Jan. 19,1982 to Finlay for Reversible running shorts; U.S. Pat. No. 4,296,498issued Oct. 27 1981 to Vinson for Reversible garment; U.S. Pat. No.4,414,691 issued Nov. 15, 1983 to Estruch for Reversible bathinggarment; U.S. Pat. No. 6,128,783 issued Oct. 10, 2000 to Blauer, et al.for Reversible sweater with opposing sides that optionally presenteither customary appearance or enhanced visibility; U.S. Pat. No.4,481,683 issued Nov. 13, 1984 to Estruch for Reversible uni-sexgarment;

Notably, typically the prior art reversible garments are characterizedby their two distinct fabrics, one forming an inside and the otherforming the outside, which are intended to be reversed inside/outsidefor different effect.

In another form of prior art, U.S. patent application Ser. No.20040048540 published Mar. 11, 2004 for inventor Dailly for Fabric forgarment and resulting garment provides a two-sided knit fabric havingtwo layers that are assembled closely together by a knitting processwith incorporation of an elastic thread. In particular, the fabriccombines sweat- repellent and thermally insulating characteristics viathese superposed layers including hollow synthetic fibers.

Thus, there remains a need for a garment formed from a single layerdouble-faced warp knit fabric having different qualities on the face andback sides, and wherein the garment is formed from a single fabric.

SUMMARY OF THE INVENTION

The present invention provides garment embodiments utilizing singlelayer double-faced warp knit fabrics having different qualities on theface and back sides of the fabric that correspond to different insideand outside surfaces of the garment, wherein the sides are aestheticallyenhanced fabrics with advantageous performance properties. The garmentembodiments may also include other suitable and appropriate warp knit orweft knit fabrics in combination with the said single layer double-facedwarp knit of the present invention in any proportion according to thegarment design. The present invention also provides methods forproducing such fabrics.

In an aspect the present invention a garment formed from a single layerfabric having a definitive two-sided, and even more desirably, twodistinctive and different colors on each side as a result.

More specifically an embodiment of the present invention provides agarment having a definitive two-sided single layer warp knit fabricstructure with a first technical back side forming the inside of thegarment including a textured micro-denier multifilament synthetic yarnsuch as nylon or polyester, preferably polyester, and a base structurecomprised of spandex elastomeric yarn, and a second technical face sideforming the outside of the garment including a fully dyeable syntheticeither continuous multifilament or a spun staple length yarn such asnylon or polyester, preferably nylon, and a second technical back sideforming the inside of the garment including a textured micro-deniermultifilament synthetic yarn such as nylon or polyester, preferablypolyester, and a base structure comprised of spandex elastomeric yarn.

Any of the conventional yarn types known in the art may be utilized toproduce a warp knit fabric for use with the performance garments of thepresent invention, including, but not limited to natural and syntheticyarns produced from spandex, nylon, polyester, viscose, cotton and/orblends thereof. In a preferred embodiment of the present invention thetechnical back-side of the single layer warp knit fabric is comprised ofa substantially resilient and thermo-settable continuous filamentsynthetic yarn. The synthetic yarn may comprise a textured multifilamentyarn, a flat non-textured multifilament yarn, or a spun staple yarnwherein the synthetic yarn comprises polyester or nylon. In the case ofa flat non-textured multifilament yarn, a higher reflectance surface canbe produced thereby imparting a metallic look effect, particularly whenthe yarn is either solution dyed, yarn dyed, or fabric piece dyed in theinto silver or gold metallic looking colors.

A particularly desirable combination is achieved when any fashionablecolor such as Navy or Red, for example, is dyed only on the yarn visiblein the technical face side of the fabric, which corresponds to theoutside of the garment, while a contrasting and different color such assilver is dyed on the yarn visible on the technical back side of thefabric, which corresponds to the inside of the garment, resulting in asilver backed fabric having any color on the reverse face of the garmentproduct. The garment may also include other types of warp knit or weftknit fabric constructions that enhance the garment in function and/oraesthetics.

A feature of the present invention is that an embodiment of the presentinvention provides a garment formed from a single layer double faced ordistinctly two-sided warp knit fabric wherein the first and seconddistinct and different yarn layers together in a tightly spacedrelationship parallel to each other.

Another feature of the present invention is that an embodiment of thepresent invention provides a multi-directional stretch performancefabric utilizing synthetic polymer spandex elastomeric yarn.

A further feature of the present invention is that a performance sportsgarment embodiment of the present invention provides for a sueded orbrushed technical back fabric surface, corresponding to the inside ofthe garment, for maximizing wearer comfort.

Embodiments of the present invention provide methods of makingperformance garments using single layer warp knitted double facedfabrics that may have a luster range from a full dull luster face, anyintermediate luster such as semi-dull or semi-bright, or a bright orhigh luster face, a Printed face, Embossed face, or Specialty Yarn facedfabric consisting of a first distinct and opaque outer technical facefabric surface, a second distinct inner technical back fabric surfacethat may be either fully dull or highly bright in luster, and that willfacilitate the manufacturing of performance sports garments in a minimalnumber of manufacturing steps.

These and other aspects of the present invention will become apparent tothose skilled in the art after a reading of the following description ofthe preferred embodiment when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a sleeveless garment constructed according tothe present invention.

FIG. 2 is a front view of an alternative, short-sleeved garmentconstructed according to the present invention.

FIG. 3 is a front view of another alternative, long-sleeved garmentconstructed according to the present invention.

FIG. 4 shows a front view of yet another alternative garment constructedaccording to the present invention.

FIG. 5 shows a front view of another alternative garment according tothe present invention.

FIG. 6 illustrates a front view of another alternative garment accordingto the present invention.

FIG. 7 illustrates a front view of another alternative garment accordingto the present invention.

FIG. 8 shows a front view of another alternative garment according tothe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description, like reference characters designate likeor corresponding parts throughout the several views. Also in thefollowing description, it is to be understood that such terms as“forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,”“downwardly,” and the like are words of convenience and are not to beconstrued as limiting terms.

Referring now to the drawings in general, the illustrations are for thepurpose of describing preferred embodiments of the invention and are notintended to limit the invention thereto. The various FIGS. 1-8 all showparticular embodiments for performance sports garments according to thepresent invention, each with some garment pattern difference, intendedto illustrate but not limit the range of garment types to which thepresent invention applies. All of the garments set forth herein areformed using a knitted fabric according to the prior filed parentapplication 10/720,947, of which this application is aContinuation-In-Part, which is incorporated herein by reference in itsentirety regarding the fabric construction, and may be used incombination with other warp knit or weft knit fabrications according toeach unique garment design embodiment.

As seen in FIG. 1, a knitted sleeveless shirt is constructed accordingto the present invention is shown. FIG. 1 shows a first fabric surface10 and a second fabric surface 12, wherein the first fabric surfacecorresponds to the inside of the garment and the second fabric surfacecorresponds to the outside of the garment, when the garment is worn inits intended orientation. Similarly, all figures show first (10) andsecond (12) fabric surfaces corresponding to the inside and outside ofthe garment, respectively.

Similarly, FIGS. 2 and 3 illustrate alternative patterns for making aknitted shirt constructed according to alternative embodiments of thepresent invention. FIG. 2 shows a short-sleeved shirt embodiment, whileFIG. 3 shows a long-sleeved shirt embodiment.

FIG. 4 illustrates a knitted pants embodiment, once again with insideand outsides of the garment indicated. FIGS. 7 and 8 show short knittedpants constructions, including sports performance underwear in FIG. 7.

FIGS. 5 and 6 show tank top embodiments, with FIG. 6 having narrowerstraps and an alternative construction. Importantly, in more delicateapparel garments, such as illustrated in FIG. 6 or even in underweargarments as in FIG. 7, it is not possible to utilize the reversiblegarment constructions according to any of the various prior art, sincecombining more than one fabric via seaming or other connection wouldrender the garment too bulky to be worn as close-fitting, lightweightsports performance apparel.

The design examples set forth in the FIGS. 1-8 in the foregoingdescription are not necessarily optimized but illustrative of what canbe done for a system and method and indicative of the preferredembodiment at the time of the invention.

The preferred embodiments of the present invention include garmentsformed from a two-sided single layer stretch warp knit fabric having afirst (face) side and a second (technical back) side identified as suchfor the purposes of the following description; it will be appreciatedthat the fabric could be reversible, in which case the first and secondside labeling may be used to more generally identify and distinguish thefabric's opposite sides, faces, or surfaces, depending on theapplication, design, and function of the fabric.

The present invention provides for performance garments formed from asingle layer double-faced or distinctly two-sided warp knit fabric thathas first and second knit parallel yarn layers forming each of a firstside and a second side of the fabric that are integrally knitted andjoined together by a series of knit courses forming a resultant singlethickness fabric which discretely secures the first and second distinctand different yarn layers together in a tightly spaced relationshipparallel to each other.

A preferred embodiment of the present invention provides a sportsperformance garment that is formed of a warp knitted single-layerperformance fabric that has optimized comfort features on the inside ofthe garment, which corresponding to the second side of the fabric, withat least one different quality on the,outside of the garment, whichcorresponds to the first side of the fabric as illustrated in thevarious embodiments shown in FIGS. 1-8.

The outer surface yarn, which is used on the surface of the second side(12) of the fabric, which corresponds to the outside of the garment,will also be the visible ingredient in the fabric therefore will be dyedinto fashion colors as desired for the appropriate end use forperformance wear garment applications. The fabric inner surfacebackside, which contacts the skin of the wearer, will thus be hiddenfrom view but provide appropriate features for the comfort of thegarment wearer.

Thus, the first and second sides of the fabric used for the garmentsaccording to the present invention advantageously provides for each sidehaving at least one different quality from the other side, wherein saidquality is either quantitatively and/or qualitatively distinguishablebetween the first and second sides. By way of example and notlimitation, said at least one different quality preferably includescolor, shade, fiber type(duplicate) fiber type, pattern, texture,chemical finish, mechanical finish or additional processing, luster orbrightness, opacity, reflectivity, and/or wherein the side differencesaffect fabric performance such as the functional features of wicking,breathability or permeability, water-resistance, stain resistance,comfort, heat transfer, insulation or cooling, flame retardant, andcombinations thereof.

In the case of color differences, the first and second sides may havedifferent colors or different shades of the same color, which may beachieved by solution dyeing, yarn dyeing, fabric piece dyeing, and thelike. Additionally or alternatively, the first and second sides may havedifferences such as one of the sides having a metallic color, look orfinish, realized by fiber type, finish, coating, and combinationsthereof.

The first and second sides of the fabric and garment may have differentfiber types in terms of the material or substance itself, or in terms ofthe form of the material, such as multifilament, textured multifilament,spun staple, and the like, and combinations thereof, which provide for adifference of at least one quality between the inside and outside of thegarment.

Another difference between the first (10) and second (12) sides of thefabric, and subsequently the inner and outer surfaces of the performancegarment in which the fabric is utilized, according to the presentinvention, includes the pattern on each side. Pattern differencesinclude printed, embossed, embroidery, specialty yarn, and knittingdifferences on either side; any variation in pattern from one side tothe other that is distinguishable is considered to fall within the scopeof the present invention, i.e., the difference need not be highlypronounced, but noticeable by a qualitative and/or quantitative measure.

The texture may also vary between the first and second sides. Thetwo-sided single layer stretch warp knit fabric is preferably formedusing a knitting technique that provides for a quality unique to eachside. The textural differences may be provided by finish-enhanced means,including but not limited to brushed, chemically treated, sueded,sanded, and the like, and combinations thereof, as well as beingoptionally provided in part due to the yarn differences, as set forthhereinabove.

Another difference between the first (10) and second (12) sides of thefabric and performance garment according to the present invention isluster and/or brightness or opacity may be one of the at least onedistinguishing quality from the first to second sides of the two-sidedsingle layer stretch warp knit fabric, which correspond to inside andoutside of the garment formed therewith, respectively, according to thepresent invention.

Another distinction between sides occurs where the side differencesaffect fabric performance, i.e., the differences between the sidesproduce a functional quality in the fabric overall, such as stainresistance and wearer comfort, more specifically the ability of theinner fabric structure inside the performance garment to efficiently andrapidly move and transport moisture away from the body of the wearer andtransfer it to the outer garment surface layer by means of a hydrophobichighly wickable ingredient such as microdenier textured polyester yarnagainst the body integrally knitted to and connected with the outerfabric face of the garment that in turn releases the moisture throughevaporation.

The present invention provides embodiments such as underwear garmentsformed from single layer double-faced warp knit fabrics having differentqualities on the face and back sides that are aesthetically enhancedfabrics with advantageous performance properties, such ascomfort-enhanced inside properties to benefit the garment wearer.

More specifically, one embodiment of the present invention provides adistinctive inside/outside sports performance garment formed from adefinitive two-sided single layer warp knit fabric structure with afirst technical face side, corresponding to the garment outside,comprised of a fully dyeable synthetic either continuous multifilamentor a spun staple length yarn such as nylon or polyester, preferablynylon, and a second technical back side, corresponding to the garmentinside, comprised of a textured micro-denier multifilament syntheticyarn such as nylon or polyester, preferably polyester, and a basestructure of the fabric comprised of spandex elastomeric yarn. A rangeof fabric weights would be suitable for the garment embodimentsaccording to the present invention, preferably, between about four toabout twelve oz/yd².

Any of the conventional yarn types known in the art may be utilized toproduce a garment according to the present invention formed from a warpknit fabric of the present invention, including, but not limited tonatural and synthetic yarns produced from spandex, nylon, polyester,viscose, cotton and/or blends thereof. In a preferred embodiment of thepresent invention a garment is formed from a two-sided single layer warpknit fabric wherein the technical back-side of the single layer warpknit fabric is comprised of a substantially resilient andthermo-settable continuous filament synthetic yarn. The synthetic yarnmay comprise a textured multifilament yarn, a flat non-texturedmultifilament yarn, or a spun staple yarn wherein the synthetic yarncomprises polyester or nylon. In the case of a flat non-texturedmultifilament yarn, a higher reflectance surface can be produced therebyimparting a metallic look effect, particularly when the yarn is eithersolution dyed, yarn dyed, or fabric piece dyed in the into silver orgold metallic looking colors. A similar look may be accomplished whenusing a preferred textured multi-filament micro-denier polyester yarnwhich optimizes moisture wicking action when against and in directcontact with the skin of the garment wearer.

Yet another embodiment of the present invention provides a sportsperformance garment utilizing a multi-directional stretch performancefabric. More particularly, in one embodiment, the multi-directionalstretch performance fabric utilizes a synthetic polymer spandexelastomeric yarn such as Lycra produced by the DuPont Company ofWilmington, De. The inclusion of spandex yarn into the fabric structureis integral to the successful execution of separation of the twodistinct yarn systems into technical face and technical back.Alternatively, a non-spandex stretch yarn, such as a stretch polyesteror extra-stretch polyester, or similar yarn having stretch propertiesmay be used, depending upon the application for the fabric, includingbut not limited to additional processing steps and/or use of the fabric,including cleaning and care or fabric maintenance, either alone or inits use as an article, such as a garment or accessory.

Another embodiment of the present invention provides for a sueded orbrushed technical back fabric surface for maximizing wearer comfort andincreasing the thermal retention properties of the fabric and garment.

Embodiments of the fabric set forth hereinabove may be advantageouslyutilized in articles of manufacture. Accordingly, the present inventionincludes articles of manufacture comprising a fabric of the presentinvention as set forth hereinabove, by way of example for performancegarments of the present invention include a short sleeved shirt, a longsleeved shirt, a tank top, and the like.

The present invention provides a method for forming a two-sided garmentincluding the steps of: providing a two-sided single layer stretch warpknit fabric comprising a first side and a second side that areintegrally formed, such that the first and second sides of the fabrichave at least one different quality from the other side, cutting thefabric into garment components using a pattern, and attachingpredetermined components to form the garment by sewing them at seams,wherein the garment has an inside and an outside corresponding to thefirst and second sides of the fabric, respectively such that the insideand the outside of the garment having at least one different qualityfrom each other.

Methods of making garments using the single layer, warp knitted, doublefaced fabrics as set forth hereinabove include methods for makingfabrics that may have a range in texture and luster from a full dullluster face, any intermediate luster such as semi-dull or semi bright,to a bright or high luster face, a printed face, embossed face, orspecialty yarn-faced fabric having a first distinct and opaque outertechnical face fabric surface, a second distinct inner technical backfabric surface that may also be in a range from fully dull to highlybright in luster, and that will facilitate the manufacturing of thegarments in a minimal number of manufacturing steps.

Further steps of processing the fabric to be utilized in the performancegarment may be performed to create at least one different qualitybetween the first and second sides of the fabric, such as, by way ofexample and not limitation: napping, brushing, sueding, chemicaltreating, finishing, printing, embossing, and combinations thereof.

Certain modifications and improvements will occur to those skilled inthe art upon a reading of the foregoing description. All modificationsand improvements have been deleted herein for the sake of concisenessand readability but are properly within the scope of the followingclaims.

1. A performance garment using a multi-directional stretch performancefabric comprising: A two-sided single layer stretch warp knit fabricfurther comprising a first side and a second side that are integrallyformed during knitting wherein each side has at least one differentquality from the other side, wherein the two-sided single layer stretchwarp knit fabric is processed to form a performance garment having aninside and outside corresponding to the first side and the second sideof the fabric, respectively.
 2. The performance garment of claim 1,wherein the processing includes cutting into components, configuring,and attaching the components to form the performance wear garment,utilizing a two-sided single layer warp knit as a main component and maybe in combination with other warp knit or weft knit fabrics, accordingto the garment design.
 3. The garment of claim 1, wherein theperformance garment is used in applications including sports, andfitness activities, as well as everyday leisure wear, casual wear, orgenerally non-sporting, non-physically exertive attire.
 4. The garmentof claim 1, wherein the fabric includes a spandex yarn component.
 5. Amethod for forming a garment comprising the steps of: providing atwo-sided single layer stretch warp knit fabric comprising a first sideand a second side that are integrally formed, such that the first andsecond sides of the fabric have at least one different quality from theother side, cutting the fabric into garment components using a pattern;attaching predetermined components to form the garment by eitherconventional sewing technology, ultrasonic welding, adhesive seaming, orany such method of fabricating a garment by joining them at seams,wherein the garment has an inside and an outside corresponding to thefirst and second sides of the fabric, respectively such that the insideand the outside of the garment having at least one different qualityfrom each other.